Absorbent Articles And Methods Of Making The Same

ABSTRACT

Disposable absorbent articles are disclosed herein along with method of making the same. The disposable absorbent article has a topsheet, a backsheet, and an absorbent system between the topsheet and the backsheet. The absorbent system has a first absorbent core and a second absorbent core which are offset from one another. An adhesive layer is disposed between the first absorbent core and the second absorbent core, at least in part.

FIELD OF THE INVENTION

The present invention pertains to disposable absorbent articles suitablefor absorbing and containing body exudates.

BACKGROUND OF THE INVENTION

A variety of disposable absorbent articles have been relied on byconsumers to handle or manage body exudates. These consumers may includebabies, toddlers, children, teenagers, adults, and elderly persons.Thus, it is clear that the types of fluids or body exudates managed bysuch articles may vary as well to include urine, feces, menses, andother discharges. Typically, in the case of adults, the articles takethe form of sanitary napkins, adult incontinence pads, and adultincontinence diapers or undergarments. One of the primary drivers of thedesirability of these products to wearers is to give them assurance thatwhen they experience incontinence, the occurrence of such will gounnoticed by others and even more ideally by the wearers.

One way of improving the performance and overall discretion ofdisposable absorbent articles that has been widely utilized bymanufacturers has been the inclusion of superabsorbent polymers whichare able to intake increased amounts of liquid and consequently form aswollen hydrogel material. The resulting hydrogel serves to retain fluidsuch as discharged body liquids within the structure.

While disposable absorbent articles with these superabsorbent materialstend to be highly absorbent and less bulky, there are a number of usersof these products that have a high body mass index (BMI) for which theseproducts still leave much to be desired. In particular, these users tendto experience exaggerated bunching of the absorbent article during wearand as a result there can be increased opportunity for leaks to occur.

Consequently, there is a need for a disposable absorbent article whichtargets to provide increased protection from leakage to consumers whichhave a high BMI while maintaining a level of discretion to the wearerwhile in use. And there is a need for a process which facilitatesmanufacturing of such disposable absorbent articles.

SUMMARY OF THE INVENTION

Described herein are disposable absorbent articles that can provideimproved protection from leakage to consumers with a wide variety ofBMI's. Additionally, processes disclosed herein can facilitatemanufacturing of such articles.

In some forms, a disposable absorbent article has a longitudinalcenterline and a lateral centerline, a first end and an opposing secondend. The disposable absorbent article further comprises: a liquidpermeable cover sheet; a liquid impermeable backsheet, the liquidpermeable cover sheet and the liquid impermeable backsheet forming atleast a portion of an outer periphery of the disposable absorbentarticle; a first absorbent core having a first width, wherein the firstabsorbent core comprises a first outer edge and a first slit edge, eachbeing generally oriented parallel to the longitudinal centerline, afirst leading edge and a first trailing edge joining each of the firstouter edge and the first slit edge at opposite ends of the firstabsorbent core; a second absorbent core having a second width, whereinthe second width is greater than the first width, wherein the secondabsorbent core comprises a second outer edge and a second slit edge,each being generally oriented parallel to the longitudinal centerline, asecond leading edge and a second trailing edge joining each of thesecond outer edge and the second slit edge at opposite ends of thesecond absorbent layer, wherein the first leading edge is disposed moreproximal the first end than the second leading edge, and wherein thesecond trailing edge is disposed more proximal to the second end thanthe first trailing edge; and a layer of adhesive disposed, at least inpart, between the first absorbent core and the second absorbent core, atleast a portion of the layer of adhesive being disposed on the liquidpermeable cover sheet or an intermediate layer between the liquidpermeable cover sheet and the first absorbent core longitudinallyoutboard of the first leading edge or the first trailing edge andwherein the layer of adhesive does not longitudinally extend beyond thesecond leading edge or the second trailing edge.

In some forms, a disposable absorbent article has a longitudinalcenterline and a lateral centerline, a first end and an opposing secondend. The disposable absorbent article further comprises: a liquidpermeable cover sheet; a liquid impermeable backsheet, the liquidpermeable cover sheet and the liquid impermeable backsheet forming atleast a portion of an outer periphery of the disposable absorbentarticle; a first absorbent core having a first width, wherein the firstabsorbent core comprises a first outer edge and a first slit edge, eachbeing generally oriented parallel to the longitudinal centerline, afirst leading edge and a first trailing edge joining each of the firstouter edge and the first slit edge at opposite ends of the firstabsorbent core, wherein the first absorbent core further comprises afirst carrier web, a first support web, and a first composition lanedisposed between the first carrier web and the first support web; asecond absorbent core having a second width, wherein the second width isgreater than the first width, wherein the second absorbent corecomprises a second outer edge and a second slit edge, each beinggenerally oriented parallel to the longitudinal centerline, a secondleading edge and a second trailing edge joining each of the second outeredge and the second slit edge at opposite ends of the second absorbentlayer, wherein the first leading edge is disposed more proximal thefirst end than the second leading edge, and wherein the second trailingedge is disposed more proximal to the second end than the first trailingedge, wherein the second absorbent core further comprises a secondcarrier web, a second support web, and a second composition lanedisposed between the second carrier web and the second support web; alayer of adhesive disposed, at least in part, between the firstabsorbent core and the second absorbent core, at least a portion of thelayer of adhesive being disposed on the liquid permeable cover sheet oran intermediate layer between the liquid permeable cover sheet and thefirst absorbent core longitudinally outboard of the first leading edgeor the first trailing edge and wherein the layer of adhesive does notlongitudinally extend beyond the second leading edge or the secondtrailing edge; and wherein the first carrier web is folded onto thefirst support web thereby forming a first outer edge, wherein the secondcarrier web is folded onto the second support web thereby forming asecond outer edge, and wherein the first outer edge and the second outeredge are disposed on opposite sides of the absorbent article.

BRIEF DESCRIPTION OF THE DRAWINGS

While the specification concludes with claims particularly pointing outand distinctly claiming the subject matter which is regarded as formingthe present invention, it is believed that the invention will be betterunderstood from the following description which is taken in conjunctionwith the accompanying drawings in which the designations are used todesignate substantially identical elements and in which:

FIG. 1 is a plan view showing an exemplary disposable absorbent articlein accordance with the present disclosure;

FIG. 2 is a cross-sectional view of the incontinence pad shown in FIG. 1taken along 2-2;

FIG. 3 is a plan view showing an exemplary absorbent system inaccordance with the present disclosure;

FIG. 4 is an elevation view showing an exemplary absorbent system inaccordance with the present disclosure;

FIG. 5 is a process schematic showing an exemplary process in accordancewith the present disclosure;

FIG. 6 is a plan view of an absorbent core web in accordance with thepresent disclosure;

FIG. 7 is an elevation view showing another exemplary absorbent systemin accordance with the present disclosure;

FIG. 8 is a process schematic showing another exemplary process inaccordance with the present disclosure;

FIG. 9A is a plan view showing a carrier web with first and secondcompositions thereon in accordance with the present disclosure;

FIG. 9B is a cross sectional view of the carrier web with first andsecond compositions shown in FIG. 9A;

FIG. 10 is a cross sectional view of the carrier web of FIG. 9B with theadditional feature of a support web in accordance with the presentdisclosure;

FIG. 11 is a cross sectional view of the web of FIG. 10 with the addedfeatures of the first and second outer edges;

FIG. 12 is a process schematic showing additional processes to theprocess of FIG. 8, in accordance with the present disclosure; and

FIG. 13 is a cross sectional view showing the web of FIG. 11 after beingsplit into a first and second absorbent core laminates.

DETAILED DESCRIPTION OF THE INVENTION

The following term explanations may be useful in understanding thepresent disclosure: “The disposable absorbent articles, particularlyincontinence pads or pants, of the present invention can provideflexibility to allow for an improved and comfortable fit which is lesssusceptible to bunching during use. In particular, it is envisioned thatthe articles of the present invention exhibit heightened structuralresiliency from the proposed configuration and orientation of the layerscontained therein. For the purposes of this disclosure, reference to anincontinence pad, disposable absorbent article, or absorbent articlewill be used. However, the present invention may be applied to aplurality of absorbent articles including, but not limited to, sanitarynapkins, pantiliners, menstrual pads, diapers, training pants, adultincontinence pants, etc.

An “elastic,” “elastomer” or “elastomeric” refers to materialsexhibiting elastic properties, which include any material that uponapplication of a force to its relaxed, initial length can stretch orelongate to an elongated length more than 10% greater than its initiallength and will substantially recover back to about its initial lengthupon release of the applied force.

As used herein, the term “joined” encompasses configurations whereby anelement is directly secured to another element by affixing the elementdirectly to the other element, and configurations whereby an element isindirectly secured to another element by affixing the element tointermediate member(s) which in turn are affixed to the other element.

“Longitudinal” means a direction running substantially perpendicularfrom a waist edge to a longitudinally opposing waist edge of anabsorbent article when the article is in a flat out, uncontracted state,or from a waist edge to the bottom of the crotch, i.e. the fold line, ina bi-folded article. Directions within 45 degrees of the longitudinaldirection are considered to be “longitudinal.” “Lateral” refers to adirection running from a longitudinally extending side edge to alaterally opposing longitudinally extending side edge of an article andgenerally at a right angle to the longitudinal direction. Directionswithin 45 degrees of the lateral direction are considered to be“lateral.”

The term “nonwoven” refers herein to a material made from continuous(long) filaments (fibers) and/or discontinuous (short) filaments(fibers) by processes such as spunbonding, meltblowing, carding, and thelike. Nonwovens do not have a woven or knitted filament pattern. Theterm “machine direction” (MD) is used herein to refer to the directionof material flow through a process. In addition, relative placement andmovement of material can be described as flowing in the machinedirection through a process from upstream in the process to downstreamin the process.

The term “cross direction” (CD) is used herein to refer to a directionthat is generally perpendicular to the machine direction.

The disposable absorbent articles, particularly incontinence pads orpants, of the present invention can provide flexibility to allow for animproved and comfortable fit which is less susceptible to bunchingduring use. In particular, it is envisioned that the articles of thepresent invention exhibit heightened structural resiliency from theproposed configuration and orientation of the layers contained therein.For the purposes of this disclosure, reference to an incontinence pad,disposable absorbent article, or absorbent article will be used.However, the present disclosure may be applied to a plurality ofabsorbent articles including, but not limited to, sanitary napkins,pantiliners, menstrual pads, diapers, training pants, adult incontinencepants, etc.

There are several factors to consider when designing a disposableabsorbent article like an incontinence pad, particularly if improved fitand performance are desired. First, the stiffness of the pad is animportant factor. Typically, thinner pads offer less stiffness thantheir bulkier counterparts. While bulkier pads may be less likely tosuccumb to the compression that is typical during wear, bulkier pads areless desirable because they can cause the incontinence pad to lose itsdiscreetness during use. Furthermore, some flexibility in the absorbentcore can allow the incontinence pad to adjust more readily to thecontours of the body of a user during use. Second, the absorbency of thepad is key in determining whether the pad is useful for consumers.Ideally, the pad is well suited to accommodate either small or largeloads of exudates. This accommodation means not only storing either typeof load sufficiently but also effectively and quickly wicking such loadsfrom a body-contacting surface of the pad such that the user experienceslittle to no feeling of wetness after the release of the load. In thecase of a small load, a wearer should be able to continue to wear thepad for some reasonable time after a release since immediate changing ofthe pad may not be feasible or desired.

In the past, incontinence pad designs have required a bit of compromiserelative to these factors. In contrast, the absorbent articles, whichinclude but are not limited to incontinence, designed pursuant to thepresent invention account for these factors to arrive at an absorbentarticle which exhibits improved protection against leakage, particularlyfor those wearers of a higher than average body mass index (BMI).Namely, incontinence pads of the present disclosure provide good coreflexibility, excellent wicking, distribution, and overall absorbency,and in certain embodiments, may include barrier cuffs which stand upduring use and contact the wearer in an appropriate location areincluded as part of the construction to further protect against alikelihood of leakage from the pad.

FIG. 1 shows an absorbent article according to the present disclosure ormore particularly an incontinence pad or sanitary napkin 10 (referred tomainly as “incontinence pad” herein) may comprise a longitudinalcenterline 80 and a lateral centerline 90. The longitudinal centerline80 generally extends parallel to the longest dimension of theincontinence pad 10. The lateral centerline 90 extends generallyperpendicular to the longitudinal centerline 80 and lies in the sameplane as the incontinence pad 10 in a flattened state on a flat surface.The lateral centerline 90 bisects the length of the incontinence pad 10where the length is parallel to the longitudinal centerline 80, and thelongitudinal centerline 80 bisects the width of the incontinence pad 10where the width is parallel to the lateral centerline 90. Additionally,as shown, the MD direction (machine direction) may be generally parallelto the longitudinal centerline 80 of the incontinence pad 10, and the CDdirection (cross-machine direction) may be generally parallel to thelateral centerline 90.

The incontinence pad 10 comprises a generally elongated oval shape.However, any suitable shape may be utilized. Some examples includehourglass (peanut), offset hourglass (one end is wider than an oppositeend and a narrowed mid-section between the ends), etc. The incontinencepad 10 may be symmetric about the longitudinal centerline 80 orasymmetric about the longitudinal centerline 80. Similarly, theincontinence pad 10 may be symmetric about the lateral centerline 90 orasymmetric about the lateral centerline 90.

The incontinence pad 10 may further comprise a chassis 20 comprising aplurality of side edges 22 and 24 which extend generally parallel to thelongitudinal centerline 80. A pair of end edges 26 and 28 join each ofthe side edges 22 and 24. One end edge 26 joins the side edges 22 and 24in the first end region 40 of the incontinence pad 10 while the otherend edge 28 joins the side edges 22 and 24 in the second end region 48of the incontinence pad 10—the second end region 48 being opposite thefirst end region 40. An intermediate region 44 is disposed between thefirst end region 40 and the second end region 48.

Incontinence pad 10 may further comprise a first fold line 50 and asecond fold line 55. The first fold line 50 can define a boundarybetween the first end region 40 and the intermediate region 44. Thesecond fold line 55 can define a boundary between the second end region48 and the intermediate region 44. The first end region 40 can bedefined by the end edge 26, the first fold line 50, and a portion of theside edges 22 and 24 disposed between the end edge 26 and the first foldline 50. The intermediate area 44 can be defined by the first fold line50, the second fold line 55, and a portion of the side edges 22 and 24disposed between the first fold line 50 and the second fold line 55. Thesecond end region 48 can be defined by the second fold line 55, end edge28, and a portion of the side edges 22 and 24 disposed between the endedge 28 and the second fold line 55. The fold lines 50 and 55 can beparallel and can be co-linear (on average) with the folds which arecreated via the packaging process for the incontinence pad 10.

The chassis 20 of FIG. 1 is shown in cross-section in FIG. 2. Amongother things, the chassis 20 comprises a primary topsheet 203. Thisprimary topsheet has a body-facing surface 203A and a garment-facingsurface 203B. This chassis 20 of the pad 10 further comprises abacksheet 207 which also comprises its own body-facing surface 207A andopposing garment-facing surface 207B. These two components sandwich anabsorbent system 205. In other words, the absorbent system 205 isdisposed between the topsheet 203 and the backsheet 207. All threecomponents (i.e., topsheet 203, backsheet 207, and absorbent system 205)form the chassis 20 of the pad 10. Additional layers may very well beincluded within this chassis 20, particularly between the topsheet 203and the backsheet 207 but it should be noted that these layers areseparate and apart from the absorbent system. Suitable additional layersmay include secondary topsheets, acquisition layers, additionaldistribution layers over and above those which will be discussed below,and other useful layers. In the case of a secondary topsheet, it isdisposed beneath the primary topsheet 203 and on the body-facing surfaceof the core. In some forms, the secondary topsheet (also known as the“STS”) has a greater length and/or width than the absorbent system 205.

In some forms, the chassis may further comprise barrier cuffs 230A and230B. The barrier cuffs are discussed in additional detail hereafter.

The chassis 20 further comprises a wearer-facing surface 20A and agarment-facing surface 20B. The wearer-facing surface 20A may comprisethe topsheet 203, and the garment-facing surface 20B may comprise thebacksheet 207.

The absorbent system 205 is formed from multiple layers and is directedto quickly acquiring the bodily fluid or exudates and distributing themalong a length of the core. FIG. 3 depicts the absorbent system of aspecific form of the present invention. A plan view of the pad 10 withthe primary topsheet 203 and backsheet 207, and any optional layers,removed for facilitated viewing of the absorbent system 205 is providedin FIG. 3. FIG. 4 shows a cross-section of this absorbent system 205 inmore detail.

Still referring to FIG. 3, in some forms, the absorbent system 205 maycomprise a first absorbent core 60 and a second absorbent core 70. Asshown, the first absorbent core 60 has a first leading edge 66 and afirst trailing edge 67 which opposes the first leading edge 66.Similarly, the second absorbent core 70 comprises a second leading edge76 and a second trailing edge 77 opposite the second leading edge 76.

The first absorbent core 60 additionally comprises a first slit edge 361and a first outer edge 363. Similarly, the second absorbent core 70comprises a second slit edge 371 and a second outer edge 373. It isworth noting that the first slit edge 361 and the second slit edge 371are shown on the same side; however, the first slit edge 361 and thesecond slit edge 371 can be positioned on opposite side of the absorbentsystem 205 as discussed in additional detail hereafter.

It is worth noting that while the slit edge can be formed via cuttingfrom a larger web as disclosed herein, it is not necessarily required.Absorbent article manufacturers could receive the first absorbent coreand the second absorbent core separate. In such instances, the need toslit the absorbent core web may be obviated. So, the term “slit edge” isutilized herein to distinguish one edge versus another rather than torequire one edge to have to have been cut from a portion of a largerweb.

Additionally, the first absorbent core 60 has a first width 369 and thesecond absorbent core 370 comprises a second width 379. As shown, thefirst width 369 may be less than the second width 379. The respectivewidths of the first absorbent core layer 60 and the second absorbentcore layer 70 are discussed hereafter.

Referring now to FIG. 4, the first absorbent core 60 has an uppersurface 60A and a lower surface 60B which opposes the upper surface.Similarly, the second absorbent core 70 has an upper surface 70A and alower surface 70B. Additionally, in some forms, the first absorbent core60 and/or the second absorbent core 70 may comprise a laminate structurewhich includes a plurality of layers, a single layer or a combination oflayers. For example, in some forms, the first absorbent core 60 maycomprise a laminate structure while the second absorbent core 70comprises a single layer or vice versa. Such forms are discussed inadditional detail hereafter.

As shown, in some forms, the first absorbent core 60 may be joined tothe second absorbent core 70 in an offset manner or configuration alongthe length of the absorbent system 205. As used herein “offset” or“offset manner” means that the layers of interest are staggered and thattheir respective leading edges or trailing edges are not aligned in az-direction (i.e., the leading edge of one layer or laminate structureis not coterminous with the trailing edge or leading edge of an adjacentunderlying or overlying layer or laminate structure) when the layers orlaminate structures overlay one another. This offset joinder of thefirst and second absorbent cores 60 and 70 results in an overlapping andjoined area of the two layers that forms a central portion 205C of theabsorbent system 205. The central portion 205C of the absorbent system205 is consequently bounded on each side by a front end portion 205F anda rear end portion 205R, both of the absorbent system 205. In otherwords, the front end portion 205F and the rear end 205R portion arerespectively disposed at opposing ends of the absorbent system 205. Asshown in some forms, a distance between the first leading edge 66 andthe second leading edge 76 can define a length of the front end portion205F. Similarly a distance between the second trailing edge 77 and thefirst trailing edge 67 can define a length of the rear end portion 205R.In some forms, the second leading edge 76 may be the leading edge of theabsorbent system 205 while the first trailing edge 67 may be thetrailing edge of the absorbent system 205.

Processing of such forms can be facilitated according to the process ofthe present disclosure. As shown in FIGS. 5 and 6, an absorbent core web500 can be obtained from a supplier or can be manufactured by anabsorbent article manufacturer or a combination thereof. Additionaldetails of the absorbent core web 500 are provided hereafter. As shown,the absorbent core web 500 can be transported in a machine direction toa slitting machine 520. Slitting machines are well known in the art.

Still referring now to FIGS. 5 and 6, in some forms, the absorbent coreweb 500 can be slit along a slit line 590 which can be offset from alongitudinal centerline 580 of the absorbent core web 500. In someforms, the slit line 590 may be colinear with the longitudinalcenterline 580. As shown, post slitting, two separate webs may becreated, namely, a first absorbent core web 560 and a second absorbentcore web 570.

The first absorbent core web 560 may then be provided to a cuttingdevice 530A while the second absorbent core web 570 may be provided to asecond cutting device 530B. The first cutting device 530A creates aplurality of discrete first absorbent cores 560A (individually referredto as the first absorbent core 60 shown in FIGS. 3 and 4) from the firstabsorbent core web 560. The second cutting device 530B creates aplurality of discrete absorbent cores 570A (individually referred to asthe second absorbent core 70 shown in FIGS. 3 and 4) from the secondabsorbent core web 570. Exemplary cutting devices are disclosed in U.S.Patent Application Publication No. 2018/0154533.

Referring now to FIGS. 3-5, as shown, the cutting device 530A canprovide the first absorbent core 60 with a convex (male) leading edge 66while the second cutting device 530B can provide the second absorbentcore 70 with a concave (female) leading edge 76. However, forms arecontemplated where both the leading edges 66 and 76 are convex (male).Forms are contemplated where both the leading edges are concave(female). Forms are contemplated where the leading edge 66 is concave(female) and the leading edge 76 is convex (male). Additional forms arecontemplated where at least one or the leading edges or trailing edgesof the first absorbent core layer 60 and/or the second absorbent corelayer 70 are neither convex nor concave, e.g. substantially flat.

Referring back to FIG. 5, from the cutting device 530A, the plurality ofdiscrete first absorbent core layers 560A is provided to a cut-and-slipor cut-and-lay operation 540A. The cut-and-slip or cut-and-layoperations position each of the plurality of discrete first absorbentcores 560A onto a carrier web at spaced apart intervals. The carrier webwill be described in additional detail hereafter. The first absorbentcore 60 (shown in FIGS. 3 and 4) that is placed onto the carrier web,may be oriented such that the convex (male) end is the leading edge inthe machine direction or the concave (female) end is the leading edge.

Similarly, from the cutting device 530B, the plurality of discretesecond absorbent cores 570A is provided to a cut-and-slip or cut-and-layoperation 540B. The cut-and-slip or cut-and-lay operations 540B positioneach of the plurality of discrete second absorbent cores 570A onto thecarrier web at spaced apart intervals. As shown, the second absorbentcore 70 (shown in FIGS. 3 and 4) can be placed onto the carrier web postthe addition of the first absorbent core 60 to the carrier web. In suchforms, the second absorbent core 70 may be provided in an offset mannersuch that its upper surface 70A (shown in FIG. 4) is attached to thelower surface 60B of the first absorbent core 60. The second absorbentcore 70 and the first absorbent core 60 may be attached in any suitablemanner, e.g. adhesives.

It is worth noting that where the first absorbent core 60 and the secondabsorbent core 70 are positioned in an offset manner and are adhesivelyattached, care should be taken as to how the adhesive is applied.Referring now to FIGS. 4 and 5, adhesive applied to the lower surface60B should be strategically positioned to reduce the likelihood ofcontamination of the equipment. For example, as shown, adhesive appliedin the front end portion 205F could contaminate the equipment as thesecond absorbent core layer 70 does not overly the adhesive in thatarea. Adhesive is needed in the central portion 205C. Additionally,adhesive should be provided in the rear end portion 205R. In such forms,adhesive would be applied to the carrier web to ensure that the secondabsorbent core 70 releases completely from the cut-and-slip orcut-and-lay operation 540B. In other forms where the second leading edge76 forms the front end portion 205F, adhesive should be applied to thecarrier web in this area to ensure that the second leading edge 76 isreleased from the cut-and-slip or cut-and-lay operation 540B.Cut-and-slip and cut-and-lay devices are well known in the art.

Still referring to FIGS. 4 and 5, from the second cut-and-slip orcut-and-lay operation 540B, a laminate structure 581 comprising thecarrier web, first absorbent core 60 and the second absorbent core 70 isprovided. From here, a backsheet web can be provided over the lowersurface 70B of the second absorbent layer 70. The backsheet web cancover the laminate structure 581. The backsheet web and the carrier webcan then be joined to encapsulate the first absorbent core layer 60 andthe second absorbent core layer 70 thereby forming an absorbent articleweb. The absorbent article web can then be provided to a cutting devicewhich cuts the absorbent article web into individual absorbent articles.

In some forms, as mentioned previously, the first absorbent core 60and/or the second absorbent core 70 may comprise a plurality of websand/or layers themselves. Referring now to FIG. 7, for example, thefirst absorbent core 60 (shown in FIGS. 3 and 4) may comprise a firstsuperabsorbent layer 61 disposed on a first distribution layer 62, i.e.a first absorbent core laminate 760. And, the second absorbent core 70(shown in FIGS. 3 and 4) may comprise a second superabsorbent layer 71disposed on a second distribution layer 72, i.e. a second absorbent corelaminate 770. In some forms, the first distribution layer 62 is joinedto the second distribution layer 72 in an offset manner or configurationalong the length of the core. This offset joinder of the first andsecond distribution layers 62, 72 results in an overlapping and joinedarea of the two laminates that forms a central portion 205C of theabsorbent system 205. The central portion 205C of the absorbent system205 is consequently bounded on each side by a front end portion 205F anda rear end portion 205R, both of the core. In other words, the front endportion 205F and the rear end 205R portion are respectively disposed atopposing ends of the absorbent system 205. As shown, the front endportion 205F is formed from the first leading edge 66 of the firstabsorbent core laminate 760 while the rear end portion 205R of the core205 is formed by the second trailing edge 77 of the second absorbentcore laminate 770.

For the form of FIG. 7, the first leading edge 66 and second trailingedge 77 of the first and second absorbent core laminates, respectively,oppose each other and form the front end portion 205F and the rear endportion 205R of the absorbent system 205, respectively or vice versa. Inother forms, the first trailing edge 67 and second leading edge 76 ofthe first and second absorbent core laminates may oppose each other andform a front end portion 205F and a rear end portion 205R of theabsorbent system 205, respectively or vice versa. In both instances, thefirst leading edge 66 and second trailing edge 77 may be in the form ofa male connection derived from a nested cut of the first and secondabsorbent cores. Similarly, the first trailing edge 67 and secondleading edge 76 may be in the form of a female connection derived from anested cut of the first and second laminates, respectively. The nestedcuts of the leading edges and trailing edges of the first and secondabsorbent core laminates are discussed in additional detail hereafter.

In an alternate form, the first absorbent core laminate 760 may bejoined to superabsorbent layer 71 instead of the second distributionlayer 72. In such forms, the laminates may be joined to one another inan offset manner as well except the first distribution layer 62 isjoined to the second superabsorbent layer 71 instead of the seconddistribution layer 72.

In some forms, the overlapping area or region that forms the centralportion 205C of the core 205 has at least one characteristic of agreater capacity, a greater void volume, or a greater thickness than thefront end portion 205F and the rear end portion 205F of the absorbentsystem 205. These forms may be particularly useful for providing forheightened leakage protection in the central portion where female usersof such pads would typically contact the pad and release fluids.

Referring back to FIG. 4, as noted previously, the first absorbent core60 and/or the second absorbent core 70 may comprise laminate structures.However, in some forms, the first absorbent core 60 and second absorbentcore layer 70 may comprise airlaid structures. However, the utilizationof airlaid structures may obviate the need for separate distributionlayers and superabsorbent layers. In other examples, at least one of thefirst absorbent core layer 60 or second absorbent core layer 70 maycomprise a laminate structure as described above with regard to FIG. 7while the other of the first absorbent core layer 60 or second absorbentcore layer 70 comprise an airlaid structure. Suitable airlaid absorbentcore structures are disclosed in U.S. Pat. Nos. 8,105,301 and 8,603,622and U.S. Patent Application Publication No. 2017/0348166.

For those forms where the first absorbent core and/or the secondabsorbent core comprise a laminate structure, processing of such formscan be facilitated according to the process of the present disclosure.As shown in FIG. 8, a carrier web 800 can be obtained from a supplier orcan be manufactured by an absorbent article manufacturer. Additionaldetails of the carrier web 800 will be provided hereafter. As shown, thecarrier web 800 can be transported in a machine direction to acomposition deposition apparatus 820. In some forms, the compositiondeposition apparatus 820 can deposit superabsorbent material onto thecarrier web 800. In some forms, the composition deposition apparatus 820can deposit a mixture of materials, e.g. superabsorbent, cellulose,stiffening fibers, etc. In some forms, the composition apparatus candeposit health benefit agents onto the carrier web 800. In some forms,multiple composition deposition apparatuses may be utilized. Compositiondeposition apparatuses are known in the art examples of which areavailable from Christy Machine & Conveyor in Fremont, Ohio. Additionalexamples of composition deposition apparatuses are described in U.S.Pat. Nos. 7,838,722; 8,180,603; 7,744,713; 8,206,533; 8,568,566; andU.S. Patent Application Publication No. 2015/0223990A1.

Referring now to FIGS. 8 through 9B, the composition depositionapparatus 820 can deposit a first composition lane 930 and a secondcomposition lane 940 on the carrier web 800 on a first portion 960 andsecond portion 963, respectively, thereby forming a composition web 812.As shown, the composition web 812 comprises a first edge 910 and anopposing second edge 920. The first and second edges 910 and 920 of thecomposition web 812 run generally parallel to the machine direction. Thefirst composition lane 930 comprises a first proximal edge 935 which isadjacent the first edge 910 of the composition web 812 and a firstdistal edge 937 which is disposed opposite the first proximal edge 935and is disposed adjacent a slit line 990. And, similar to the first edge910 and second edge 920 of the composition web 812, the first proximaledge 935 and the first distal edge 937 are generally oriented parallelto the machine direction. A first composition width 931 is defined by anaverage distance between the first proximal edge 935 and the firstdistal edge 937.

As shown, the second composition lane 940 is spaced apart from the firstcomposition lane 930 in the cross machine direction. An intermediatelane 950 is disposed between the first composition lane 930 and thesecond composition lane 940. Similar to the first composition lane 930,the second composition lane 940 comprises a second proximal edge 945which is adjacent to the second edge 920 of the composition web 812.Opposite the second proximal edge 945, a second distal edge 947 isdisposed adjacent to a centerline 980 of the composition web 812. Thesecond proximal edge 945 and the second distal edge 947 are generallyoriented parallel to the machine direction. A second composition width941 is defined by an average distance between the second proximal edge945 and the second distal edge 947. In some forms, a ratio of the firstcomposition width 931 to the second composition width 941 can be fromabout 1 to 1, 0.9 to 1; 0.7 to 1; 0.5 to 1, specifically including allvalues within these ranges and any ranges created thereby.

The intermediate lane 950 has a width which is defined by the averagedistance between the first distal edge 937 and the second distal edge947. In some forms, the intermediate lane 950 width can be less thanabout 11 mm, less than about 9 mm, less than about 7 mm, less than about6 mm, less than about 4 mm, specifically reciting all values withinthese ranges and any ranges created thereby. However, it is believedthat a minimum width should be about 3 mm. The 3 mm width of theintermediate lane 950 may allow for appropriate processing of thecomposition web 812. For example, where the composition deposited is aparticulate material, the first edge 910 and second edge 920 of thecomposition web 812 may need to be folded or otherwise sealed toencapsulate the particulate material. Such folding or sealing can reducethe likelihood of contamination of the processing equipment by theparticulate material. The inventors believe that below a 3 mm width (1.5mm allowance for the first composition lane and 1.5 allowance for thesecond composition lane) that such contamination reduction measures maybe much more difficult to achieve.

Referring now to FIGS. 8 through 11, subsequent the formation of thecomposition web 812, a support web 870 is provided to the compositionweb 812. The support web 870 may be produced by a consumer goodsmanufacturer or may obtained from a supplier of such materials. Asshown, the support web 870 may be provided by a roll 875 of support webmaterial. The support web 870 is provided on an upper surface of thefirst composition lane 930 and on an upper surface of the secondcomposition lane 940 thereby forming an absorbent laminate web 814. Thesupport web 870 comprises a first surface 870A and an opposing secondsurface 870B. The support web 870 can have a first support web edge 871and a second support web edge 873 opposite the first support web edge871. The first support web edge 871 and the second support web edge 873extend generally parallel to the machine direction. As shown, thesupport web 870 may overlap the first composition lane 930 and thesecond composition lane 940 such that the first support web edge 871 isdisposed outboard of the first proximal edge 935 and the second supportweb edge 873 is disposed outboard of the second proximal edge 945.

In some forms, after the application of the support web 870 to thecomposition web 812, the absorbent laminate web 814 is folded via afolding unit operation 830 such that the first edge 910 of the carrierweb 800 is folded over and attached to the first surface 870A of thesupport web 870. Folding the first edge 910 forms the first outer edge363. Similarly, the second edge 920 of the carrier web 800 may be foldedover and attached to the first surface 870A of the support web 870.Folding the second edge 920 forms the second outer edge 373. Theabsorbent laminate web 814 post the folding unit operation 830 is thefolded absorbent laminate web 816.

Folding unit operations are well known in the art of absorbent articlemanufacture. However, for those forms where the carrier web 800 issealed to the support web 870 to form outer edges 363 and 373, adistance between the first edge 910 of the carrier web 800 and the firstproximal edge 835 may need to be carefully planned. Again, where thecomposition that is imparted onto the carrier web 800 is particulatematerial, the creation of outer edges 363 and 373, whether via foldingof the carrier web 800, folding of the support web 870, or sealing theedges of the carrier web 800 and support web 870 together, can reducethe likelihood of contamination of the equipment. In some forms, a firstoffset distance 913 between the first edge 910 and the first proximaledge 935 can be at least about 3 mm, greater than 3 mm, greater than 7mm, greater than 10 mm, greater than 13 mm, or at least 17 mm,specifically including all values within these ranges and any rangescreated thereby. A second offset distance 917 between the second edge920 and the second proximal edge 945 may be similarly configured as thefirst offset distance 913. It is worth noting that a larger offsetdistance, e.g. 913 and/or 917, can impact the amount of composition inthe first lane 930 and/or the amount of composition in the second lane940. Accordingly, the offset distances 913 and 917 should be less thanabout 35 mm, less than about 30 mm, or less than about 25 mm,specifically reciting all values within these ranges and any rangescreated thereby.

Additionally, in some forms, in conjunction with the first offsetdistance 913 and/or second offset distance 917, or independent thereof,a distance between the first proximal edge 935 and the first support webedge 871 can be at least about 2.5 mm, at least about 3 mm, or at leastabout 4.5 mm, specifically including all values within these ranges andany ranges created thereby. A distance between the second proximal edge945 and the second support web edge 873 may be configured similarly.Again, the above values can facilitate the creation of the outer edges363 and 373 which can reduce the likelihood that particulate material inthe first and/or second composition lanes contaminate processingequipment. However, much like the larger offset distances mentionedpreviously, larger distances between the proximal edges and the supportweb edges can have an impact on the amount of composition in the firstlane 930 and/or second lane 940. Accordingly, these distances should beless than about 35 mm, less than about 25 mm, or less than about 15 mm,specifically reciting all values within these ranges and any rangescreated thereby.

After the creation of the outer edges 363 and 373, the folded absorbentlaminate web 816 may then be provided to a slitting unit operation 840.Slitting unit operations are well known in the art. Still referring toFIGS. 8-11, the slitting operation can cut the folded absorbent laminateweb 816 along a slit line 990 which in some forms, may be offset from acenterline 980 of the folded laminate web 816. In some forms, the slitline 990 may be colinear with the longitudinal centerline 980. As shown,post slitting, two separate webs may be created, namely, a firstabsorbent core web 1060 and a second absorbent core web 1070.Additionally, in some forms, edges of the carrier web 800 and supportweb 870 created via the slitting operation may be sealed together, e.g.folded, similar to the outer edges 363 and 373 to reduce the likelihoodof contamination by compositions in the first lane 930 and/or secondlane 940.

Referring now to FIG. 12, the first absorbent core web 1060 may then beprovided to a cutting device 850A while the second absorbent core web1070 may be provided to a second cutting device 850B. The first cuttingdevice 850A creates a plurality of discrete first absorbent corelaminates 1060A from the first absorbent core web 1060. The secondcutting device 850B creates a plurality of discrete absorbent corelaminates 1070A from the second absorbent core web 1070. Exemplarycutting devices are disclosed in U.S. Patent Application Publication No.2018/0154533.

For the sake of clarity, individual first absorbent core laminates 1060Aof the plurality may be referred to as the first absorbent corelaminates 760 (shown in FIG. 7), and individual second absorbent corelaminates 1070A of the plurality may be referred to as the secondabsorbent core laminates 770 (shown in FIG. 7). As each of the pluralityof first absorbent core laminate 1060A and second absorbent corelaminates 1070A may be constructed as described herein with regard tothe first absorbent core laminates 760 and the second absorbent corelaminates 770, such designation facilitates discussion.

Referring now to FIGS. 3, 7, and 12 as shown, the cutting device 850Acan provide the first absorbent core laminate 760 with a convex (male)leading edge 66 while the second cutting device 850B can provide thesecond absorbent core laminate 770 with a concave (female) leading edge76. However, forms are contemplated where both the leading edges 66 and76 are convex (male). Forms are contemplated where both the leadingedges are concave (female). Forms are contemplated where the leadingedge 66 is concave (female) and the leading edge 76 is convex (male).Additional forms are contemplated where at least one or the leadingedges or trailing edges of the first absorbent core laminates 760 and/orthe second absorbent core laminate 770 are neither convex nor concave,e.g. substantially flat.

It is worth noting that where convex and concave edges are desired onthe ends of the absorbent cores, whether single layers or laminates,care should be taken with regard to the cross machine directiontracking. If the web enters into the cutting device such that the webcenterline does not match the cutting device centerline in the machinedirection, then the curvature on the concave edges could be skewed. Thisskewed edge could create one side of the edge having a tail, e.g. alonger end. If too long of a tail is created, then part of the corecould end up in a perimeter product seal (crimp) which could lead to aquality defect. To minimize the likelihood of this quality defect, thecenterline of the webs entering the cutting device should be within 1sigma value, i.e. plus or minus 2.5 mm of the cutting device centerline.Where entering web are outside of this 1 sigma value, a web trackingdevice can be utilized to correct the tracking of the entering web suchthat the desired tolerances are achieved. Web tracking devices are knownin the art.

Referring back to FIG. 12, from the cutting device 850A, the pluralityof discrete first absorbent core laminates 1060A is provided to acut-and-slip or cut-and-lay operation 860A. The cut-and-slip orcut-and-lay operation can position each of the plurality of discretefirst absorbent core laminates 1060A (individually referred to as firstabsorbent core laminates 760) on a wearer-facing web, e.g. a topsheetweb, a secondary topsheet web, or on a combination web of the topsheetand secondary topsheet at spaced apart intervals. The placement of thediscrete first absorbent core portions 1060A onto the wearer-facing webforms a hybrid web 1018A. In some forms, the carrier web 800 (shown inFIGS. 9A-11 and 13) may be the wearer-facing web. Additional detailsregarding the carrier web are provided hereafter. The first absorbentcore laminate 760 (shown in FIG. 7) that is placed onto the web, may beoriented such that the convex (male) end is the leading edge in themachine direction or the concave (female) end is the leading edge.

Similarly, from the cutting device 850B, the plurality of discretesecond absorbent core laminates 1070A is provided to a cut-and-slip orcut-and-lay operation 860B. The cut-and-slip or cut-and-lay operation860B can position each of the plurality of discrete second absorbentcore laminates 1070A (individually referred to as second absorbent corelaminates 770) onto the hybrid web 1018A at spaced apart intervals. Insuch forms, the second absorbent core laminate 770 may be provided in anoffset manner such that its upper surface 70A (shown in FIG. 7) isattached to the lower surface 60B of the first absorbent core laminate760. The second absorbent core laminate 770 and the first absorbent corelaminate 760 may be attached in any suitable manner, e.g. adhesives.

It is worth noting that where the first absorbent core laminate 760 andthe second absorbent core laminate 770 are positioned in an offsetmanner and are adhesively attached, care should be taken as to how theadhesive is applied. Referring back to FIG. 7, adhesive applied to thelower surface 60B should be strategically positioned to reduce thelikelihood of contamination of the equipment. For example, as shown,adhesive applied in the front end portion 205F could contaminate theequipment as the second absorbent core laminate 770 does not overly theadhesive in that area. Adhesive is needed in the central portion 205C.Additionally, adhesive should be provided in the rear end portion 205R.In such forms, adhesive would be applied to the carrier web to ensurethat the second absorbent core laminate 770 releases completely from thecut-and-slip or cut-and-lay operation 860B. In other forms where thesecond leading edge 76 forms the front end portion 205F, adhesive shouldbe applied to the carrier web in this area to ensure that the secondleading edge 76 is released from the cut-and-slip or cut-and-layoperation 860B. Cut-and-slip and cut-and-lay devices are well known inthe art.

In some forms, the cut-and-slip or cut-and-lay operation 860B can invertthe second absorbent core laminate 770. For example, as shown in FIGS.7, 12, and 13, the second absorbent core laminate 770 can be rotatedabout an axis that is generally parallel to the machine direction. Thecombination of the first absorbent core laminate 760 and the secondabsorbent core laminate 770 creates a laminate structure web 1080. Insome forms of the laminate structure web 1080, the first and secondouter edges 363 and 373 are positioned on the same side. And oppositethe first and second outer edges 363 and 373, the first slit edge 361and the second slit edge 371 are positioned on the same side of thelaminate structure web 1080. Still in other forms, the second absorbentcore laminate 770 may be placed on the first absorbent core laminate 760such that the carrier web of the second absorbent laminate is in contactwith the support web 870 of the first absorbent core laminate 760, e.g.the first and second outer edges 363 and 373 are disposed on oppositesides of the laminate structure web 1080.

From the second cut-and-slip or cut-and-lay operation 860B, the laminatestructure web 1080 comprising the first absorbent core laminate 760 andthe second absorbent core laminate 770 is provided. And as notedpreviously, in some forms, the laminate structure web 1080 may comprisethe wearer-facing web in combination with the foregoing. From here, abacksheet web can be provided over the lower surface 70B of the secondabsorbent core laminate 770. The backsheet web can cover the laminatestructure web 1080. The backsheet web and the carrier web and/orwearer-facing web can then be joined to encapsulate the first absorbentcore laminate 760 and the second absorbent core laminate 770 therebyforming an absorbent article web. The absorbent article web can then beprovided to a cutting device which cuts the absorbent article web intoindividual absorbent articles.

The inventors have also found that either upstream or downstream of thecut and slip and/or cut and lay operations described herein in FIGS. 5and 12, that core orientation may be monitored to reduce the likelihoodof mis-oriented cores. For example, where the first superabsorbent layerand/or the second super absorbent layer are desired to be oriented moreproximal to the wearer, a vision sensor may be utilized. Or, even wherethe first distribution layer and/or the second distribution layer aredesired to be more proximal to the wearer, a vision sensor may beutilized. While a vision system may be utilized to determine theorientation of the absorbent layers of the absorbent articles of thepresent disclosure, vision systems can be bulky and costly to purchaseand operate. In contrast, a vision sensor can cost considerably lessthan a vision system and may not require the space of the vision system.

The vision sensor can be programmed to recognize the texture of opposingsides of the superabsorbent layers. For example, the carrier webutilized herein can be fairly smooth. In contrast, the compositionsdeposited upon the carrier web, e.g. AGM, can have a much roughersurface. The vision sensor can be programmed to “see” the difference inthe roughness of the carrier web versus that of the compositiondeposited thereon. In doing so, the vision sensor can then provide abinary output, e.g. a 1 or 0, to a central processing unit (CPU). Thesignal can be a 0 for the correct orientation versus a 1 for theincorrect orientation. Additionally, the CPU can be programmed such thatthe CPU monitors a moving average of articles, e.g. articles 1-101, then2-102, etc. The moving average can be utilized to determine if theincorrect orientation, e.g. a 1, is sustained for more than simply a fewarticles. Any suitable vision sensor may be utilized. One specificexample includes the vision sensor available from Keyence and sold underthe trade name IV-HG500MA.

Applicant shall now provide more detailed insight into the individualcomponents of the disposable absorbent articles envisioned herein.

Primary Topsheet

Referring back to FIG. 2, the primary topsheet 203 (also referred toherein “topsheet”) of the chassis 20 is positioned adjacent abody-facing surface 203A of the absorbent system 205 and may be joinedthereto and to the backsheet 207 by attachment methods (not shown) suchas those well known in the art. Suitable attachment methods aredescribed with respect to joining the backsheet 207 to the absorbentsystem 205. The topsheet 203 and the backsheet 207 may be joineddirectly to each other in the incontinence pad periphery and may beindirectly joined together by directly joining them to the absorbentsystem 205 or additional optional layers within the chassis like asecondary topsheet which spans the entire or partial area of thearticle. This indirect or direct joining may be accomplished byattachment methods which are well known in the art.

The absorbent article may comprise any known or otherwise effectiveprimary topsheet, such as one which is compliant, soft feeling, andnon-irritating to the wearer's skin. Suitable primary topsheet materialsinclude a liquid pervious material that is oriented towards and contactsthe body of the wearer permitting bodily discharges to rapidly penetratethrough it without allowing fluid to flow back through the topsheet tothe skin of the wearer. The primary topsheet, while being capable ofallowing rapid transfer of fluid through it, also provides for thetransfer or migration of the lotion composition onto an external orinternal portion of a wearer's skin. A suitable topsheet can be made ofvarious materials such as woven and nonwoven materials; apertured filmmaterials including apertured formed thermoplastic films, aperturedplastic films, and fiber-entangled apertured films; hydro-formedthermoplastic films; porous foams; reticulated foams; reticulatedthermoplastic films; thermoplastic scrims; or combinations thereof. Somesuitable examples of films that can be utilized as topsheets aredescribed in U.S. Pat. Nos. 3,929,135; 4,324,246; 4,342,314; 4,463,045;5,006,394; 4,609,518; and 4,629,643.

Nonlimiting examples of woven and nonwoven materials suitable for use asthe topsheet include fibrous materials made from natural fibers,modified natural fibers, synthetic fibers, or combinations thereof. Somesuitable examples are described in U.S. Pat. Nos. 4,950,264, 4,988,344;4,988,345; 3,978,185; 7,785,690; 7,838,099; 5,792,404; and 5,665,452.

In some forms, the topsheet may comprise tufts as described in U.S. Pat.Nos. 8,728,049; 7,553,532; 7,172,801; 8,440,286; 7,648,752; and7,410,683. The primary topsheet may have a pattern of discrete hair-likefibrils as described in U.S. Pat. No. 7,655,176 or 7,402,723. Additionalexamples of suitable topsheet includes those described in U.S. Pat. Nos.8,614,365; 8,704,036; 6,025,535 and in U.S. Patent ApplicationPublication No. 2016/0129661.

Another suitable primary topsheet or a primary topsheet combined with asecondary topsheet may be formed from a three-dimensional substrate asdetailed in a U.S. Patent Application Publication No. 2017/0258647 A1.

The primary topsheet may have one or more layers, as described in U.S.Patent Application Publication Nos. 2016/0167334 A1; 2016/0166443 A1;2017/0258651 A1. The topsheet may be apertured as disclosed in U.S. Pat.No. 5,628,097, to Benson et al., issued on May 13, 1997.

Secondary Topsheet

As noted previously, the disposable absorbent articles of the presentdisclosure may comprise additional layers, one of which includes asecondary topsheet. As mentioned previously, the secondary topsheet maybe separate and apart from the absorbent system. Additionally, thesecondary topsheet is disposed beneath the primary topsheet 203 and onthe body-facing surface of the core. In some forms, the secondarytopsheet may have a basis weight from about 40 gsm to about 100 gsm,from about 45 gsm to about 75 gsm, or from about 50 gsm to about 60 gsm,specifically including all values within these ranges and any rangescreated thereby. In some forms, the secondary topsheet may comprise ahomogeneous mix of fibers.

Some exemplary secondary topsheets are described in U.S. PatentApplication Publication Nos. 2015/0351976 A1 and 2014/0343523 A1; andU.S. Patent Application Serial No. 2018/0098893. Forms are contemplatedwhere the carrier web 800 (shown in FIGS. 9B-11) comprises a secondarytopsheet.

Backsheet

The backsheet 207 of the chassis 20 may be positioned adjacent agarment-facing surface of the absorbent system 205 and may be joinedthereto by attachment methods (not shown) such as those well known inthe art. For example, the backsheet 207 may be secured to the absorbentsystem 205 by a uniform continuous layer of adhesive, a patterned layerof adhesive, or an array of separate lines, spirals, or spots ofadhesive. Alternatively, the attachment methods may comprise using heatbonds, pressure bonds, ultrasonic bonds, dynamic mechanical bonds, orany other suitable attachment methods or combinations of theseattachment methods as are known in the art. Forms of the presentdisclosure are also contemplated wherein the absorbent system 205 is notjoined to the backsheet 207, the topsheet 203, or both.

The backsheet 207 may be impervious, or substantially impervious, toliquids (e.g., urine) and may be manufactured from a thin plastic film,although other flexible liquid impervious materials may also be used. Asused herein, the term “flexible” refers to materials which are compliantand will readily conform to the general shape and contours of the humanbody. The backsheet 207 may prevent, or at least inhibit, the exudatesabsorbed and contained in the absorbent system 205 from wetting articlesof clothing which contact the incontinence pad 10 such as undergarments.However, in some instances, the backsheet 207 may permit vapors toescape from the absorbent system 205 (i.e., is breathable) while inother instances the backsheet 207 may not permit vapors to escape (i.e.,non-breathable). Thus, the backsheet 207 may comprise a polymeric filmsuch as thermoplastic films of polyethylene or polypropylene. A suitablematerial for the backsheet 207 is a thermoplastic film having athickness of from about 0.012 mm (0.5 mil) to about 0.051 mm (2.0 mils),for example. Any suitable backsheet known in the art may be utilizedwith the present invention.

Some suitable examples of backsheets are described in U.S. Pat. Nos.5,885,265; 4,342,314; and 4,463,045. Suitable single layer breathablebacksheets for use herein include those described for example in GB A2184 389, GB A 2184 390, GB A 2184 391, U.S. Pat. Nos. 4,591,523,3,989,867, 3,156,242; WO 97/24097 and U.S. Pat. Nos. 6,623,464;6,664,439 and 6,436,508.

The backsheet may have two layers: a first layer comprising a gaspermeable aperture formed film layer and a second layer comprising abreathable microporous film layer as described in U.S. Pat. No.6,462,251. Suitable dual or multi-layer breathable backsheets for useherein include those exemplified in U.S. Pat. Nos. 3,881,489, 4,341,216,4,713,068, 4,818,600, EP 203 821, EP 710 471, EP 710 472, and EP 793952.

Absorbent System

The absorbent system 205 of the present invention may comprise anysuitable shape including but not limited to an oval, a discorectangle, arectangle, an asymmetric shape, and an hourglass. For example, in someforms of the present invention, the absorbent system 205 may comprise acontoured shape, e.g. narrower in the intermediate region than in theend regions. As yet another example, the absorbent system may comprise atapered shape having a wider portion in one end region of the pad whichtapers to a narrower end region in the other end region of the pad. Theabsorbent system 205 may comprise varying stiffness in the MD and CD.

As detailed earlier, the absorbent system 205 comprises the firstabsorbent core and the second absorbent core. And as described hereinthe first absorbent core and/or the second absorbent core may comprise asingle layer or multiple layers. Both are generally compressible,conformable, non-irritating to the wearer's skin, and capable ofabsorbing and retaining liquids such as urine and other certain bodyexudates including menses.

The configuration and construction of the absorbent system 205 may vary(e.g., the absorbent system 205 may have varying caliper zones, ahydrophilic gradient, a superabsorbent gradient, or lower averagedensity and lower average basis weight acquisition zones). Further, thesize and absorbent capacity of the absorbent system 205 may also bevaried to accommodate a variety of wearers. However, the total absorbentcapacity of the absorbent system 205 should be compatible with thedesign loading and the intended use of the disposable absorbent articleor incontinence pad 10.

In some forms of the present disclosure, the absorbent system 205 maycomprise a plurality of multi-functional layers that are in addition tothe first and second absorbent cores. For example, the absorbent system205 may comprise a core wrap (not shown) useful for enveloping the firstand second laminates and other optional layers. The core wrap may beformed by two nonwoven materials, substrates, laminates, films, or othermaterials. In a form, the core wrap may only comprise a single material,substrate, laminate, or other material wrapped at least partially arounditself.

The absorbent system 205 of the present disclosure may comprise one ormore adhesives, for example, to help immobilize the SAP or otherabsorbent materials within the first and second laminates.

Absorbent cores comprising relatively high amounts of SAP with variouscore designs are disclosed in U.S. Pat. No. 5,599,335 to Goldman et al.,EP 1,447,066; WO 95/11652; U.S. Pat. Publ. No. 2008/0312622A1; and WO2012/052172. These may be used to configure the superabsorbent layers.

Additions to the core of the present disclosure are envisioned. Inparticular, potential additions to the current multi-laminate absorbentcore are described in U.S. Pat. Nos. 4,610,678; 4,673,402; 4,888,231;4,834,735; 5,234,423; and 5,147,345. These are useful to the extent theydo not negate or conflict with the effects of the below described layersof the absorbent core of the present invention.

The first and second absorbent cores layers and/or laminates of theabsorbent system 205 have been detailed earlier but it is important tonote that these layers or laminates may have cross-direction widths thatare the same as each other or different. As discussed previously, forexample, the first absorbent core layer or laminate may have a lessercross-direction width than said second absorbent core layer or laminateor a greater cross-direction width than said second absorbent core layeror laminate. Forms are contemplated where the first and second absorbentcore layers comprise the same width along at least a portion of theirrespective lengths. Some particular forms, the width of the absorbentcore layers should have a width which is at least 2 mm narrower than thenarrowest portion of the pad. This can help reduce the likelihood thateither of the first absorbent core layer and/or second absorbent corelayer end up in an area which is meant to be crimped/sealed. In general,if either of the absorbent core layers ends up in the crimp, then leakscould develop in those areas where the core is in the crimp. As leakageis generally perceived as a negative attribute by wearers of absorbentarticles, leakage which is avoidable should be avoided.

In certain instances, the first and second absorbent core layers orlaminates can have machine-direction lengths that are the same while inother instances, the first and second absorbent cores havemachine-direction lengths that are different. In the latter instance,the first absorbent core layer or laminate may have a lessermachine-direction length than the second absorbent core layer orlaminate, or conversely the first absorbent core layer or laminate mayhave a greater machine-direction length than said second absorbent corelayer or laminate.

The first and second absorbent core layers or laminates in some forms,may further comprise an optional intermediate layer disposed between therespective superabsorbent layer and distribution layer. This optionalintermediate layer may comprise materials detailed herein relative tothe optional layers for the chassis, in general.

Additionally, in some forms, in addition to the first and secondabsorbent cores layers or laminates, the absorbent article orincontinence pad may further comprise an optional additional absorbentcore comprising a superabsorbent layer and/or a distribution layer. Thisoptional additional core may take the form of a third, fourth, fifth, oreven additional layers. The superabsorbent layer and distribution layermay exhibit the same or different properties detailed earlier withrespect to the first and second superabsorbent and distribution layers.Any optional additional cores may be disposed on a body-facing surfaceof the first absorbent core or second absorbent core or on agarment-facing surface of the first absorbent core or second absorbentcore.

As stated previously, in some forms, the first absorbent core layer orlaminate has a first leading edge 66 that is complementary in shape toits respective first trailing edge 67. More specifically, the firstleading edge 66 of the first absorbent core layer or laminate mayconform shapewise to the first trailing edge 67 of the same. The sameconformance may apply to the second absorbent core layer or laminate.This conformation results from a nested cut of the first absorbent corelayer or laminate and the second absorbent core layer or laminate thatprovides matching or shape fitting ends. Likewise, this feature may alsobe prevalent in any optional absorbent cores that might be incorporatedinto the absorbent system. This nesting or nested cut feature of theabsorbent cores allow for reduced waste of trim during manufacture. Ithas also been found that it is possible to configure the first andsecond absorbent core layers or laminates in a manner that allows fortheir respective convex edges to oppose one another when the first andsecond distribution layers are overlapped and joined forming anabsorbent system with a central portion 205C comprising an overlappingarea.

Referring to FIGS. 3 and 7, as noted previously, the front end portionof the absorbent system 205F can be formed from a first leading edge 66or second trailing edge 77 of either the first absorbent core or thesecond absorbent core. A rear end portion of the absorbent system 205Ris similarly formed from a first leading edge 66 or the second trailingedge 77 of the other of the first absorbent core or the second absorbentcore. This configuration yields an absorbent system with matching (i.e.,a male connection) ends. In other forms, a front end portion of theabsorbent system may be formed from a first leading edge 66 or a secondtrailing edge 77 of either the first absorbent core or the secondabsorbent core while the rear end portion of the absorbent system isformed from a first trailing edge 67 or a second leading edge 76 of theother of the first absorbent core or second absorbent core. In suchforms, the second end is shaped as a female connection and thereforedoes not match the front end portion of the same core. In other forms,the front end portion of the absorbent system may be formed from thefirst trailing edge 67 of the first absorbent core or the second leadingedge 76 of the second absorbent core. A rear end portion of theabsorbent system may be similarly formed from the first trailing edge 67of the remaining first absorbent core or the second leading edge 76 ofthe second absorbent core. This configuration yields an absorbent systemwith matching (i.e., a female connection) ends. It should be noted,however, that the width of the first and second absorbent cores may bethe same or different as mentioned herein. The nested cuts of theleading edges and trailing edges of each of the first and secondabsorbent cores can have shapes selected from the group consisting ofarcs, semicircles, semi-ellipses, chevrons, rectangles, sinusoids,jigsaws, and combinations thereof.

In some forms, the first or second absorbent cores may include one ormore recessed areas that run along the machine direction or crossdirection. These recessed areas may coincide with the discontinuouspatterns of one or more of a superabsorbent layer and distributionlayer, whether it be of the first absorbent core, second absorbent core,or both. These recessed areas may also merely be formed by embossing ofthe first or second absorbent cores. These recessed areas mayalternatively be formed by slitting, cutting, ring-rolling, or otherwiseproviding mechanical deformation through the first and/or secondabsorbent cores. Each manner of recessed area formation mentioned hereinis intended to yield a recessed area that is capable of providing apoint of preferential bending of the overall article. For instance, aplurality of recessed areas either gaps or embossed channels may beprovided in at least one or both of the first and second absorbent coresof absorbent system 205, in the machine direction. These recessed areasneed not be present in both first and second absorbent cores along theentirety of each of their lengths. The recessed areas may be present inthe machine direction only in the overlapping joinder area of the firstand second absorbent cores. Alternatively, the recessed areas may bepresent in the in the cross direction along the length of the first andsecond absorbent cores, or only in the overlapping joinder of the twoabsorbent cores. In instances like these, the laminates through whichthe recessed areas are effected will be prone to bending more easily. Ininstances where a recessed area is present in only one of a first andsecond absorbent cores, it is expected that there will be a preferentialtendency for the pad to bend at the recessed area. This means if thefirst absorbent core is closer to the body than the second absorbentcore, the pad will likely bend away from the body. The opposite may betrue as well in the event the second absorbent core placed away from thebody comprises a recessed area and the first absorbent core does not. Inthis instance, the pad may exhibit preferential tendency to bend towardthe body. Depending on the overall configuration of the pad, either typeof bending may be preferred in a particular instance.

Additionally, for those forms where the first absorbent core and/or thesecond absorbent core do not comprise laminate structures, an airlaidcore material can be utilized. Any suitable airlaid core can beutilized. Airlaid core material can be obtained by a manufacturer ofsuch materials or can be made online via equipment known in the art.Where an airlaid core is utilized, the need for separate superabsorbentlayers and distribution layers may be reduced.

Superabsorbent Layers

The first and second superabsorbent layers 61, 71 of the first andsecond absorbent cores 60, 70 comprise superabsorbent polymers orabsorbent gelling materials (AGM). In some forms, the superabsorbentlayer 61 and/or 71 may comprise the carrier web and composition. In suchforms, superabsorbent may be deposited on the carrier web to form thesuperabsorbent layers. The superabsorbent layers may comprise AGMparticles or AGM fibers. In general, such AGM's have been used only fortheir fluid-absorbing properties. Such materials form hydrogels oncontact with liquid (e.g., with urine, blood, and the like). One highlypreferred type of hydrogel-forming, absorbent gelling material is basedon the hydrolyzed polyacids, especially neutralized polyacrylic acid.Hydrogel-forming polymeric materials of this type are those which, uponcontact with fluids (i.e., liquids) such as water or body fluids, imbibesuch fluids and thereby form hydrogels. In this manner, fluid dischargedinto the fluid absorbent structures herein can be acquired and held.These preferred superabsorbent polymers will generally comprisesubstantially water-insoluble, slightly cross-linked, partiallyneutralized, hydrogel-forming polymer materials prepared frompolymerizable, unsaturated, acid-containing monomers.

The size of the fluid absorbent gelling material particles may vary overa wide range. For reasons of industrial hygiene, average particle sizessmaller than about 30 microns are less desirable. Particles having asmallest dimension larger than about 2 mm may also cause a feeling ofgrittiness in the absorbent article, which is undesirable from aconsumer aesthetics standpoint. Furthermore, rate of fluid absorptioncan be affected by particle size. Larger particles have very muchreduced rates of absorption. Fluid absorbent gelling material particlespreferably have a particle size of from about 30 microns to about 2 mmfor substantially all of the particles. “Particle Size” as used hereinmeans the weighted average of the smallest dimension of the individualparticles.

In some forms, the absorbent cores or portions thereof of the presentdisclosure may be substantially free of airfelt and are thus distinctfrom mixed layers that may include airfelt. As used herein,“substantially free of airfelt” means less than 5%, 3%, 1%, or even 0.5%of airfelt. In some forms, there may be no measurable airfelt in thesuperabsorbent layers. In the case of the first superabsorbent layer, itis preferably disposed onto the first distribution layerdiscontinuously. And as noted previously, the second superabsorbentlayer may, in conjunction with the first superabsorbent layer orindependently thereof, be disposed on the second distribution layerdiscontinuously. As used herein “discontinuously” or “in a discontinuouspattern” means that the superabsorbent polymers are applied onto thefirst distribution layer in a pattern of disconnected shaped areas.These areas of superabsorbent polymers or areas free of superabsorbentpolymer may include, but are not limited to linear strips, non-linearstrips, circles, rectangles, triangles, waves, mesh, and combinationsthereof. The first superabsorbent layer like the second superabsorbentlayer may, however, be disposed onto its respective distribution layerin a continuous pattern. As used herein “continuous pattern” or“continuously” means that the material is deposited and or secured to asuperabsorbent carrier material and/or the adjacent distribution layerin an uninterrupted manner such that there is rather full coverage ofthe distribution layer by the superabsorbent polymer.

In certain embodiments, the first and second superabsorbent layers maycomprise superabsorbent polymers that are the same. In otherembodiments, the first and second superabsorbent layers may comprisesuperabsorbent polymers that are different from one another. This is maybe in addition to the different deposition patterns that are discussedabove.

The superabsorbent layers are disposed having a thickness of 0.2 mm, 0.3mm, 0.4 mm, or 0.5 mm to 1 mm, 1.2 mm, 1.4 mm, 1.8 mm, or 2 mm. Thefirst and second superabsorbent layers may have the same or differentcross-direction widths as applied to their respective distributionlayers. For instance, the cross-direction widths of the first and secondsuperabsorbent layers may be from 20 mm, 25 mm, 30 mm, 35 mm, or 40 mmto 50 mm, 60 mm, 65 mm, 70 mm, 80 mm, or 90 mm. Alternatively, inembodiments where the widths of the first and second superabsorbentlayers differ from one another in the cross-direction width, the firstsuperabsorbent layer may have a lesser cross-direction width than thesecond superabsorbent layer. In particular, the first superabsorbentlayer may have a cross-direction width that is less than about 95%, 90%,80%, 70%, or even 60% of the width of the second superabsorbent layer.

In certain embodiments, the one or both of the first and secondsuperabsorbent layers span greater than greater than about 50%, 60%,70%, 80%, 90%, or even 95% of the cross-direction width of asuperabsorbent carrier layer and/or the respective adjoining first orsecond distribution layer.

Carrier Webs/Optional Layers

Recall that carrier webs may comprise the primary topsheet and/or thesecondary topsheet. And, like the optional layers that may be includedin the chassis, the absorbent system may also comprise similar optionallayers. The following descriptions and attributes of the optional layersare also suitable for use in the carrier web. For the sake of facility,the term “webs” shall encompass the optional layer web as well ascarrier webs. The optional layers and/or carrier webs may be websselected from the group consisting of a fibrous structure, an airlaidweb, a wet laid web, a high loft nonwoven, a needlepunched web, ahydroentangled web, a fiber tow, a woven web, a knitted web, a flockedweb, a spunbond web, a layered spunbond/melt blown web, a carded fiberweb, a coform web of cellulose fiber and melt blown fibers, a coform webof staple fibers and melt blown fibers, and layered webs that arelayered combinations thereof.

These optional layers and/or carrier webs may comprise materials such ascreped cellulose wadding, fluffed cellulose fibers, airfelt, and textilefibers. The materials of the webs may also be fibers such as, forexample, synthetic fibers, thermoplastic particulates or fibers,tricomponent fibers, and bicomponent fibers such as, for example,sheath/core fibers having the following polymer combinations:polyethylene/polypropylene, polyethylvinyl acetate/polypropylene,polyethylene/polyester, polypropylene/polyester, copolyester/polyester,and the like. The optional layers may be any combination of thematerials listed above and/or a plurality of the materials listed above,alone or in combination. The materials of the webs may be hydrophobic orhydrophilic depending on their placement within the chassis.

The materials of the webs may comprise constituent fibers comprisingpolymers such as polyethylene, polypropylene, polyester, and blendsthereof. The fibers may be spunbound fibers. The fibers may be meltblownfibers. The fibers may comprise cellulose, rayon, cotton, or othernatural materials or blends of polymer and natural materials. The fibersmay also comprise a superabsorbent material such as polyacrylate or anycombination of suitable materials. The fibers may be monocomponent,bicomponent, and/or biconstituent, non-round (e.g., capillary channelfibers), and may have major cross-sectional dimensions (e.g., diameterfor round fibers) ranging from 0.1-500 microns. The constituent fibersof the nonwoven precursor web may also be a mixture of different fibertypes, differing in such features as chemistry (e.g. polyethylene andpolypropylene), components (mono- and bi-), denier (micro denier and >20denier), shape (i.e., capillary and round) and the like. The constituentfibers may range from about 0.1 denier to about 100 denier.

The webs may include thermoplastic particulates or fibers. Thematerials, and in particular thermoplastic fibers, may be made from avariety of thermoplastic polymers including polyolefins such aspolyethylene (e.g., PULPEX™) and polypropylene, polyesters,copolyesters, and copolymers of any of the foregoing.

Depending upon the desired characteristics, suitable thermoplasticmaterials include hydrophobic fibers that have been made hydrophilic,such as surfactant-treated or silica-treated thermoplastic fibersderived from, for example, polyolefins such as polyethylene orpolypropylene, polyacrylics, polyamides, polystyrenes, and the like. Thesurface of the hydrophobic thermoplastic fiber may be renderedhydrophilic by treatment with a surfactant, such as a nonionic oranionic surfactant, e.g., by spraying the fiber with a surfactant, bydipping the fiber into a surfactant or by including the surfactant aspart of the polymer melt in producing the thermoplastic fiber. Uponmelting and resolidification, the surfactant will tend to remain at thesurfaces of the thermoplastic fiber. Suitable surfactants includenonionic surfactants such as Brij 76 manufactured by ICI Americas, Inc.of Wilmington, Del., and various surfactants sold under the Pegosperse™by Glyco Chemical, Inc. of Greenwich, Conn. Besides nonionicsurfactants, anionic surfactants may also be used. These surfactants maybe applied to the thermoplastic fibers at levels of, for example, fromabout 0.2 to about 1 g/cm² of thermoplastic fiber.

Suitable thermoplastic fibers may be made from a single polymer(monocomponent fibers), or may be made from more than one polymer (e.g.,bicomponent fibers). The polymer comprising the sheath often melts at adifferent, typically lower, temperature than the polymer comprising thecore. As a result, these bicomponent fibers provide thermal bonding dueto melting of the sheath polymer, while retaining the desirable strengthcharacteristics of the core polymer.

Suitable bicomponent fibers for use in the webs of this disclosure mayinclude sheath/core fibers having the following polymer combinations:polyethylene/polypropylene, polyethylvinyl acetate/polypropylene,polyethylene/polyester, polypropylene/polyester, copolyester/polyester,and the like. Particularly suitable bicomponent thermoplastic fibers foruse herein are those having a polypropylene or polyester core, and alower melting copolyester, polyethylvinyl acetate or polyethylene sheath(e.g., DANAKLON™, CELBOND™, or CHISSO™ bicomponent fibers). Thesebicomponent fibers may be concentric or eccentric. As used herein, theterms “concentric” and “eccentric” refer to whether the sheath has athickness that is even, or uneven, through the cross-sectional area ofthe bicomponent fiber. Eccentric bicomponent fibers may be desirable inproviding more compressive strength at lower fiber thicknesses. Suitablebicomponent fibers for use herein may be either uncrimped (i.e., unbent)or crimped (i.e., bent). Bicomponent fibers may be crimped by typicaltextile means such as, for example, a stuffer box method or the gearcrimp method to achieve a predominantly two-dimensional or “flat” crimp.

The length of bicomponent fibers may vary depending upon the particularproperties desired for the fibers and the web formation process.Typically, in an airlaid web, these thermoplastic fibers have a lengthfrom about 2 mm to about 12 mm long such as, for example, from about 2.5mm to about 7.5 mm long, and from about 3.0 mm to about 6.0 mm long.Nonwoven fibers may be between 5 mm long and 75 mm long, such as, forexample, 10 mm long, 15 mm long, 20 mm long, 25 mm long, 30 mm long, 35mm long, 40 mm long, 45 mm long, 50 mm long, 55 mm long, 60 mm long, 65mm long, or 70 mm long. The properties-of these thermoplastic fibers mayalso be adjusted by varying the diameter (caliper) of the fibers. Thediameter of these thermoplastic fibers is typically defined in terms ofeither denier (grams per 9000 meters) or decitex (grams per 10,000meters). Suitable bicomponent thermoplastic fibers as used in an airlaidmaking machine may have a decitex in the range from about 1.0 to about20 such as, for example, from about 1.4 to about 10, and from about 1.7to about 7 decitex.

The compressive modulus of these thermoplastic materials, and especiallythat of the thermoplastic fibers, may also be important. The compressivemodulus of thermoplastic fibers is affected not only by their length anddiameter, but also by the composition and properties of the polymer orpolymers from which they are made, the shape and configuration of thefibers (e.g., concentric or eccentric, crimped or uncrimped), and likefactors. Differences in the compressive modulus of these thermoplasticfibers may be used to alter the properties, and especially the densitycharacteristics, of the respective thermally bonded fibrous matrix.

The webs may also include synthetic fibers that typically do notfunction as binder fibers but alter the mechanical properties of thefibrous webs. Synthetic fibers include cellulose acetate, polyvinylfluoride, polyvinylidene chloride, acrylics (such as Orlon), polyvinylacetate, non-soluble polyvinyl alcohol, polyethylene, polypropylene,polyamides (such as nylon), polyesters, bicomponent fibers, tricomponentfibers, mixtures thereof and the like. These might include, for example,polyester fibers such as polyethylene terephthalate (e.g., DACRON™, andKODEL™) high melting crimped polyester fibers (e.g., KODEL™ 431 made byEastman Chemical Co.) hydrophilic nylon (HYDROFIL™), and the like.Suitable fibers may also hydrophilized hydrophobic fibers, such assurfactant-treated or silica-treated thermoplastic fibers derived from,for example, polyolefins such as polyethylene or polypropylene,polyacrylics, polyamides, polystyrenes, polyurethanes and the like. Inthe case of nonbonding thermoplastic fibers, their length may varydepending upon the particular properties desired for these fibers.Typically they have a length from about 0.3 to 7.5 cm, such as, forexample from about 0.9 to about 1.5 cm. Suitable nonbondingthermoplastic fibers may have a decitex in the range of about 1.5 toabout 35 decitex, such as, for example, from about 14 to about 20decitex.

Distribution Layers

The first and second distribution layers are useful for wicking bodilyfluids away from the skin of a wearer to facilitate comfort of continuedwear after a release. In some forms, the support web may comprise thedistribution layer. In some forms, the support web may be configuredsimilar to the carrier web described herein. In some forms, the firstand second distribution layers of the first and/or second laminates notonly face one another but are joined in an offset manner to form part ofthe core. The distribution layers comprise one or more of cellulose andcommuted wood pulp. This may be in the form of airlaid. The airlaid maybe chemically or thermally bonded. In particular, the airlaid may bemulti bonded airlaid (MBAL). In this instance, the distribution layermay further comprise a fibrous thermoplastic adhesive material at leastpartially bonding the airlaid to itself and adjacent distributionlayers, superabsorbent layers, or other additional (optional) layers. Itshould be noted that the same materials that are suitable for theoptional layers of the chassis are envisioned as suitable for use in thedistribution layers. The basis weight for each of the first and seconddistribution layers range from 80 gsm, 80 gsm, 100 gsm, 110 gsm, 120gsm, or 130 gsm to 140 gsm, 150 gsm, 160 gsm, 180 gsm, 200 gsm, 220 gsm,or 240 gsm. A preferred basis weight is 135 gsm for each of thedistribution layers of the first and second laminates. The support web870 (shown in FIGS. 8. 10, 11, and 13) may comprise the same makeup asthe distribution layer.

Health Benefit Agents

As noted previously, in some forms, health benefit agents may bedeposited on the carrier webs described herein. Some suitable healthbenefit agents include prebiotics, e.g. oligofructose, clay, e.g.laponite, activated charcoal, carbon, organic acids, e.g. lactic acid,xylitol, and/or antioxidants, e.g. vitamin C. In some forms,combinations of such actives may be provided on the carrier web or inother portions of the absorbent article, e.g. topsheet, barrier cuffs,secondary topsheet, distribution layers, or any combination thereof.Health benefit agents are disclosed in additional detail in U.S. Pat.No. 8,552,251.

Barrier Cuffs

Referring back to FIG. 2, the incontinence pad 10 may further comprise afirst barrier cuff 230A and a second barrier cuff 230B and fasteningadhesive 211 disposed on the garment-facing surface 20B of the chassis20. As shown, the fastening adhesive 211 may not extend out laterally tothe same extent as the absorbent system 205. As such, constructionswhere pad curl is reduced would be beneficial.

The first barrier cuff 230A and the second barrier cuff 230B may beattached to the chassis 20 in any suitable location. For example, asshown, the first barrier cuff 230A and the second barrier cuff 230B maybe attached to a wearer-facing surface 20A of the chassis 20. As shown,the first barrier cuff 230A and the second barrier cuff 230B areattached to the primary topsheet 203. In some forms, the first barriercuff 230A and the second barrier cuff 230B may be attached to agarment-facing surface 20B of the chassis 20. For example, the firstbarrier cuff 230A and the second barrier cuff 230B may be attached tothe backsheet 207. Some examples of other suitable barrier cuffs aredescribed in U.S. Pat. Nos. 4,695,278; 4,704,115; 4,795,454; 4,909,803;U.S. Patent Application Publication No. 2009/0312730.

As shown, in some forms, the first barrier cuff 230A comprises a firstcover 231 and a first elastic member 233. The second barrier cuff 230Bcomprises a second cover 235 and a second elastic member 237. As shown,the first cover 231 may fully enclose the first elastic member 233.Similarly, the second cover 235 may fully enclose the second elasticmember 237.

While the first barrier cuff 230A and the second barrier cuff 230B areshown as discrete elements which are attached to the chassis 20, anysuitable configuration may be utilized. For example, the first cover 231and/or the second cover 235 may comprise a portion of the primarytopsheet 203 and/or a portion of the backsheet 207. In such forms, thefirst barrier cuff 230A and/or the second barrier cuff 230B may beintegrally formed with the chassis 20. A form where the first barriercuff 230A and the second barrier cuff 230B are integrally formed withthe chassis 20 is shown in FIG. 2 and discussed hereafter.

The first elastic member 233 and the second elastic member 237 may beattached to the first cover 231 and the second cover 235, respectively,by any suitable means. In one example, the first elastic member may beadhesively attached to the first cover 231. Similarly, the secondelastic member 237 may be adhesively attached to the second cover 235.For example, as shown, first adhesive portions 251 and 253 may attachthe elastic members 233 and 237 to their respective covers 231 and 235.Similarly, second adhesive portions 255 and 257 may attach theirrespective covers 231 and 235 to the primary topsheet 203. As describedbelow, the first elastic member 233 and the second elastic member 237may be attached in only a portion the first cover 231 and second cover235, respectively. Additional forms are contemplated where the firstelastic member 233 and/or the second elastic member 237 are attached tothe chassis 20 in conjunction with or independently from theirrespective covers 231 and 235.

As shown, the elastic members 233 and 237 may be disposed laterallyinboard of side edges 205A and 205B of the absorbent system 205. Inother forms, the elastic members 233 and 237 may be disposed laterallyoutboard of the side edges 205A and 205B of the absorbent system 205.Still in other forms, the elastic members 233 and 237 may be disposedlaterally inboard of the side edges 205A and 205B of the absorbentsystem 205 in the first end region 40 and the second end region 48 butlaterally outboard of side edges 205A and 205B of the absorbent system205 in the intermediate region 44. Additional forms are contemplatedwhere the elastic members 233 and 237 are disposed laterally inboard ofthe side edges 205A and 205B of the absorbent system 205 in the firstend region 40 but are disposed outboard of the side edges 205A and 205Bof the absorbent system 205 in the intermediate region 44 and/or thesecond end region 48.

The elastic members comprised by the barrier cuffs can be glued in, invarious glue lengths using various glues and glue amounts andplacements. Placement of the glue is yet another variable which shouldbe considered especially when designed with the core flexibility inmind. Gluing of the elastic members and the covers create anchor pointson the pad.

The covers of the barrier cuffs of the present invention can be made ofvarying types of nonwovens of different MD and CD flexibility. The covercan be bonded to the topsheet of the absorbent article, such as, forexample, by a slot coated stripe of adhesive, glue beads, ultrasonicsealing, or other suitable bonding agents. In certain forms of thepresent invention, the cover can be bonded to the backsheet at the sideedges 22 and 24 (see FIG. 1) of the pad, such as, for example, using acrimp or other suitable bonding agents, such as, for example, adhesive.

Elastic members may comprise any suitable elastic material. Somesuitable examples include Spandex™ or other similar polyurethanes,natural or synthetic rubber, styrene block copolymers, metallocenepolyolefins, Lycra™, or any other suitable elastomer materials known inthe art. Preferably the elastic member is durable for ease of processingand for during the use of the article and exhibits excellent elasticity(recovery after strain) even under strains as high as 400%.

Additionally, the elastic members of the present disclosure may compriseany suitable dtex. In other forms, the elastic members may comprise adtex of 680 or less. In some forms, the elastic members may have a dtexbetween 680 and 470, specifically including all numbers within the rangeand any ranges created thereby.

Minimum spacing between the first barrier cuff 230A and the secondbarrier cuff 230B may be largely driven by female anatomy. However,tradeoffs can occur where the barrier cuffs (and their respectiveelastic members) are disposed too far outboard of the absorbent system205 and too far inboard of the absorbent system 205. As such, spacingbetween the most distal elastic members of their respective barriercuffs should be carefully selected. Starting from the narrowest width,spacing between the most distal elastic members of the first barriercuff 230A and the second barrier cuff 230B should be large enough toallow sufficient access to the absorbent system 205 during use whilealso taking into account the forces which will be applied to the pad. Iftoo narrow, access to a portion of the absorbent system 205 could beobstructed which could lead to leakage despite the barrier cuffs 230Aand 230B. In some forms of the present invention, minimum spacingbetween the elastic member of the first barrier cuff 230A and theelastic member of the second barrier cuff 230B which are most distal toone another may be at least 20 mm. Any suitable spacing may be utilized.For example, in some forms of the present invention, the spacing may begreater than or equal to about 20 mm, greater than about 30 mm, greaterthan about 33 mm, greater than about 35 mm, greater than about 40 mm,greater than about 45 mm, greater than about 50 mm, greater than about54 mm, greater than about 60 mm, greater than about 65 mm, less than orequal to about 70 mm, or less than about 65 mm, or less than about 60mm, less than about 55 mm, less than about 50 mm, less than about 45 mm,less than about 40 mm, less than about 35 mm, less than about 30 mm,less than about 25 mm, specifically including any values within theseranges or any ranges created thereby.

Test Methods Linear Distances

Linear distances may be measured by any appropriate instrument that iscalibrated and capable of a measurement to the nearest 0.1 mm

Basis Weight Test

A 9.00 cm² large piece of sample substrate, i.e., 1.0 cm wide by 9.0 cmlong, is used. The sample may be cut out of a consumer product, such anabsorbent article. The sample needs to be dry and free from othermaterials like glue or dust. Samples are conditioned at 23° Celsius (±2°C.) and at a relative humidity of about 50% (±5%) for 2 hours to reachequilibrium. The weight of the cut nonwoven substrate is measured on ascale with accuracy to 0.0001 g. The resulting mass is divided by thespecimen area to give a result in g/m² (gsm). Repeat the same procedurefor at least 20 specimens from 20 identical consumer products orpackaging materials therefor. If the consumer product or packagingmaterials therefor are large enough, more than one specimen can beobtained from each. An example of a sample is a portion of a topsheet ofan absorbent article. If the local basis weight variation test is done,those same samples and data are used for calculating and reporting theaverage basis weight.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm.”

Every document cited herein, including any cross referenced or relatedpatent or application and any patent application or patent to which thisapplication claims priority or benefit thereof, is hereby incorporatedherein by reference in its entirety unless expressly excluded orotherwise limited. The citation of any document is not an admission thatit is prior art with respect to any invention disclosed or claimedherein or that it alone, or in any combination with any other referenceor references, teaches, suggests or discloses any such invention.Further, to the extent that any meaning or definition of a term in thisdocument conflicts with any meaning or definition of the same term in adocument incorporated by reference, the meaning or definition assignedto that term in this document shall govern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

What is claimed is:
 1. A disposable absorbent article having alongitudinal centerline and a lateral centerline, a first end and anopposing second end, the disposable absorbent article furthercomprising: a liquid permeable cover sheet; a liquid impermeablebacksheet, the liquid permeable cover sheet and the liquid impermeablebacksheet forming at least a portion of an outer periphery of thedisposable absorbent article; a first absorbent core having a firstwidth, wherein the first absorbent core comprises a first outer edge anda first slit edge, each being generally oriented parallel to thelongitudinal centerline, a first leading edge and a first trailing edgejoining each of the first outer edge and the first slit edge at oppositeends of the first absorbent core; a second absorbent core having asecond width, wherein the second width is greater than the first width,wherein the second absorbent core comprises a second outer edge and asecond slit edge, each being generally oriented parallel to thelongitudinal centerline, a second leading edge and a second trailingedge joining each of the second outer edge and the second slit edge atopposite ends of the second absorbent layer, wherein the first leadingedge is disposed more proximal the first end than the second leadingedge, and wherein the second trailing edge is disposed more proximal tothe second end than the first trailing edge; a layer of adhesivedisposed, at least in part, between the first absorbent core and thesecond absorbent core, at least a portion of the layer of adhesive beingdisposed on the liquid permeable cover sheet or an intermediate layerbetween the liquid permeable cover sheet and the first absorbent corelongitudinally outboard of the first leading edge or the first trailingedge and wherein the layer of adhesive does not longitudinally extendbeyond the second leading edge or the second trailing edge.
 2. Thedisposable absorbent article of claim 1, wherein the first absorbentcore comprises a carrier web, a support web, and a first compositionlane disposed between the carrier web and the support web, wherein thecarrier web is joined to the liquid permeable cover sheet or a secondarytopsheet, and wherein the carrier web is folded onto the support websuch that the carrier web forms a first outer edge.
 3. The disposableabsorbent article of claim 2, wherein the first composition comprises afirst proximal edge and the carrier web comprises a first edge, andwherein a distance between the first proximal edge and the first edge isbetween 3 mm and 35 mm.
 4. The disposable absorbent article of claim 2,wherein the second absorbent core comprises a carrier web, a supportweb, and a second composition lane disposed between the carrier web andthe support web, wherein the second composition lane has a secondproximal edge and the carrier web has a second edge, and wherein adistance between the second proximal edge and the second edge is between3 mm and 35 mm.
 5. The disposable absorbent article of claim 4, whereinthe first composition lane and the second composition lane comprisedifferent basis weights of material.
 6. The disposable absorbent articleof claim 4, wherein the first composition lane and the secondcomposition lane comprise the same basis weight of material.
 7. Thedisposable absorbent article of claim 4, wherein the first absorbentcore comprises a first surface and an opposing second surface, whereinthe second surface is formed at least in part by the support web, andwherein the second absorbent core comprises a first surface and anopposing second surface, wherein first surface of the second absorbentcore is joined to the second surface of the first absorbent core, andwherein the first surface of the second absorbent core is formed atleast in part by the support web.
 8. The disposable absorbent article ofclaim 4, wherein the carrier web is folded onto the support web suchthat the carrier web forms a second outer edge.
 9. The disposableabsorbent article of claim 1, wherein the first absorbent core comprisesa carrier web, wherein the carrier web of the first absorbent core isfolded onto the support web such that the carrier web forms a firstouter edge, wherein the second absorbent core comprises a carrier web,wherein the carrier web of the second absorbent core is folded onto thesupport web such that the carrier web forms a second outer edge, andwherein the first outer edge and the second outer edge are disposed onopposite sides of the disposable absorbent article.
 10. The disposableabsorbent article of claim 1, wherein the first leading edge is convexand the first trailing is concave.
 11. The disposable absorbent articleof claim 10, wherein the second leading edge is concave and the secondtrailing edge is convex.
 12. The disposable absorbent article of claim1, wherein the second absorbent core is at least 2 mm wider than thefirst absorbent core.
 13. The disposable absorbent article of claim 1,wherein the first absorbent core comprises a carrier web, wherein thecarrier web of the first absorbent core is folded onto the support websuch that the carrier web forms a first outer edge, wherein the secondabsorbent core comprises a carrier web, wherein the carrier web of thesecond absorbent core is folded onto the support web such that thecarrier web forms a second outer edge, and wherein the first outer edgeand the second outer edge are disposed on the same side of thedisposable absorbent article.
 14. The disposable absorbent article ofclaim 1, wherein the absorbent article comprises an intermediate layerbetween the liquid permeable cover sheet and the first absorbent core.15. The disposable absorbent article of claim 1, wherein the firstabsorbent core comprises a first carrier web, a first support web, and afirst composition lane disposed between the first carrier web and thefirst support web, wherein the second absorbent core comprises a secondcarrier web, a second support web, and a second composition lanedisposed between the second carrier web and second support web.
 16. Thedisposable absorbent article of claim 15, wherein the first compositionlane has a first lane width and the second composition lane has a secondlane width, and wherein the first width is less than the second width.17. The disposable absorbent article of claim 15, wherein the firstabsorbent core is narrower than the second absorbent core.
 18. Adisposable absorbent article having a longitudinal centerline and alateral centerline, a first end and an opposing second end, thedisposable absorbent article further comprising: a liquid permeablecover sheet; a liquid impermeable backsheet, the liquid permeable coversheet and the liquid impermeable backsheet forming at least a portion ofan outer periphery of the disposable absorbent article; a firstabsorbent core having a first width, wherein the first absorbent corecomprises a first outer edge and a first slit edge, each being generallyoriented parallel to the longitudinal centerline, a first leading edgeand a first trailing edge joining each of the first outer edge and thefirst slit edge at opposite ends of the first absorbent core, whereinthe first absorbent core further comprises a first carrier web, a firstsupport web, and a first composition lane disposed between the firstcarrier web and the first support web; a second absorbent core having asecond width, wherein the second width is greater than the first width,wherein the second absorbent core comprises a second outer edge and asecond slit edge, each being generally oriented parallel to thelongitudinal centerline, a second leading edge and a second trailingedge joining each of the second outer edge and the second slit edge atopposite ends of the second absorbent layer, wherein the first leadingedge is disposed more proximal the first end than the second leadingedge, and wherein the second trailing edge is disposed more proximal tothe second end than the first trailing edge, wherein the secondabsorbent core further comprises a second carrier web, a second supportweb, and a second composition lane disposed between the second carrierweb and the second support web; a layer of adhesive disposed, at leastin part, between the first absorbent core and the second absorbent core,at least a portion of the layer of adhesive being disposed on the liquidpermeable cover sheet or an intermediate layer between the liquidpermeable cover sheet and the first absorbent core longitudinallyoutboard of the first leading edge or the first trailing edge andwherein the layer of adhesive does not longitudinally extend beyond thesecond leading edge or the second trailing edge; and wherein the firstcarrier web is folded onto the first support web thereby forming a firstouter edge, wherein the second carrier web is folded onto the secondsupport web thereby forming a second outer edge, and wherein the firstouter edge and the second outer edge are disposed on opposite sides ofthe absorbent article.